Manufacturing%20Operations%20Management

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Manufacturing Operations Management

• Dennis Brandl Peter Owen
• BRL Consulting Eli Lilly Co

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Objectives

• Review the ISA 95 standards and how they are
  being used in companies like Eli Lilly Company
  for shop floor to top floor integration
• The standards provide a formal model for
  exchanged data between business systems and
  manufacturing systems
• The models also include a definition of
  Manufacturing Operations Management, the
  activities on the shop floor that take production
  schedules and perform the actual work required to
  manufacture products
• The Manufacturing Operations Management models
  are currently being used in the development of
  multiple new manufacturing facilities

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Manufacturing in the Supply Chain

• Make is a significant part of the supply chain
  and collaborative manufacturing, but is often the
  last element to be actually integrated
• Collaboration in Make is usually not a Low
  Hanging Fruit
• But can offer very high ROI for high volume, or
  high cost products
• However, Business IT and Manufacturing IT
  organizations are often at odds as they try to
  collaborate
• They have different goals and different success
  criteria
• They use the same terms for different elements
  and different terms for the same elements

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Collaborative Manufacturing Help

• Fortunately there are multiple standards in place
  to help integrating business systems with
  manufacturing systems.
• The ISA 95 Enterprise/Control System Integration
  standards, also an IEC/ISO standard
• XML Schemas standards for collaborative
  manufacturing from the World Batch Forum
• Will show how they are being applied to the
  development of manufacturing systems roadmap

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Different Points of View

• Business Systems
• Time Horizons
• Long-term view
• Model detail
• Linear route structures
• Control emphasis
• Product cost and overall profitability
• Modeling criteria
• Accounting reference points
• Has inventory value changed significantly? If
  not, dont model separately
• View from the boardroom

• Manufacturing Systems
• Time Horizons
• Real-time view
• Model detail
• Complex routes with rework paths
• Control emphasis
• Physical movement accountability
• Modeling criteria
• material movement reference points
• Does product stop moving? If not, dont model
  separately
• View from the workcenter

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Philosophical Orientation

• Enterprise Management systems
• How much is my stuff worth?
• Manufacturing Opearations Systems
• Where is my stuff?

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ISA 95 Provides Direction

• The ANSI/ISA 95.00.01 Enterprise - Control
  System Integration - Part 1 Models and
  Terminology
• Also Draft International Standard ISO/IEC 62264-1
• ANSI/ISA 95.00.02 Enterprise - Control System
  Integration - Part 2 Object Attributes
• Draft ISA 95.00.03 Enterprise - Control System
  Integration - Part 3 Activity Models of
  Manufacturing Operations Management

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ISA95.01 Levels
Level 4
Business Planning Logistics Plant Production
Scheduling, Operational Management, etc
Interface addressed in the ISA 95.01 and ISA
95.02 standard
Level 3
Manufacturing Operations Control Dispatching
Production, Detailed Production Scheduling,
Reliability Assurance, ...
Area addressed in the ISA 95.03 standard
Levels 2,1,0
Batch Control
Discrete Control
Continuous Control
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ISA95.01 Levels
Business Logistics Management (ERP)
Level 4
Business Planning Logistics Plant Production
Scheduling, Operational Management, etc
Interface addressed in the ISA 95.01 and ISA
95.02 standard
Manufacturing Operations Management (MES, LIMS,
AM, )
Level 3
Manufacturing Operations Control Dispatching
Production, Detailed Production Scheduling,
Reliability Assurance, ...
Area addressed in the ISA 95.03 standard
Levels 2,1,0
Batch Control
Discrete Control
Continuous Control
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ISA 95 Part 1 and Part 2 Exchanged Information

• Information that crosses the boundary between
  business systems and manufacturing systems

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Exchanged Information Categories
Enterprise Information Plant Production
Scheduling, Operational Management, etc
Production Schedule (What to make and use)
Production Performance (What was made and used)
Product Definition Information (How to make a
product)
Production Capability Information (What
is available for use)
Manufacturing Control Information Area
Supervision, Production Planning, Reliability,
Assurance, etc
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4x4 Object Models

• Four categories of resources
• Personnel
• Equipment
• Material (and Energy)
• Process Segments
• Four Process, Product, Production Models
• Capability Capacity Definition
• Product Definition
• Production Schedule
• Production Performance

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Four Resource Object Models
Personnel resources managed for production
Equipment resources managed for production
Material resources managed for production
Business view of production processes
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Capability, Product, Schedule, and Performance
Information
What is available for use for production
What is needed to make a product
What to make and resources to use
What was made and resources actually used
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Production Schedule

• What to make
• Priority and/or dates
• What materials to use
• What equipment to use
• What personnel to use
• Production parameters (e.g. Color, Options,)

• Production Schedule
• Production Request
• Segment Request
• Expected Produced Material
• Expected Consumed Material
• Expected Personnel
• Expected Equipment
• Production Parameters

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Production Performance

• What was made
• What material was actually produced
• What materials were actually consumed
• Equipment used
• Personnel used
• Production data (e.g. Purity, density,)

• Production Performance
• Production Response
• Segment Response
• Produced Material Actual
• Consumed Material Actual
• Personnel Actual
• Equipment Actual
• Production Data

Per location (Site, Area, ) Per shift, hour,
end of batch,
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XML Standard for B2M Exchanges

• The World Batch Forum has developed XML Schemas
  that map to the ANSI/ISA-95 models
• Defines how to represent the ISA-95 information
  in XML
• Business To Manufacturing Markup Language
• B2MML
• One schema for each object model
• Formal way to exchange information
• www.wbf.org

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An XML Example Material Lot
ltMaterial ltMaterialLotgt ltIDgt W89 lt/IDgt
ltDescriptiongt A lot of material lt/Descriptiongt
ltMaterialDefinitionIDgt WXE908
lt/MaterialDefinitionIDgt ltLocationgt Tank 1
lt/Locationgt ltQuantity UnitOfMeasure
"KL" gt 4500 lt/Quantitygt
ltMaterialLotPropertygt ltIDgt
dateTimeProduction lt/IDgt ltValuegt
2001-01-06T0014231130 lt/Valuegt
lt/MaterialLotPropertygt ltMaterialLotPropertygt
ltIDgt Quality Status lt/IDgt ltValuegt Good
lt/Valuegt lt/MaterialLotPropertygt lt/MaterialLo
tgt lt/Materialgt
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ISA95 Part 3 Activity Models of Manufacturing
Operations

• In Development
• Expected Release 2004

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Order Processing (1.0)
Product Cost Accounting (8.0)
Product Shipping Admin (9.0)
Production Scheduling (2.0)
PRODUCTION OPERATIONS
INVENTORY OPERATIONS
Material and Energy Control (4.0)
Product Inventory Control (7.0)
Production Control (3.0)
INVENTORY OPERATIONS
QUALITY ASSURANCE OPERATIONS
Procurement (5.0)
MAINTENANCE OPERATIONS
Quality Assurance (6.0)
Marketing Sales
Maintenance Management (10.0)
ResearchDevelopment and Engineering
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ISA 95.03 Manufacturing Operations Functions
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Other Enterprise Activities in Manufacturing
Operations

• Some actives are not specific to manufacturing
• ISA-95.03 lists references to standards in these
  areas

Major Activities Within Manufacturing Operations
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Implementations

• Nestle
• Project to use the XML schemas for schedule
  exchange
• Arla Foods
• Project to use XML for standard interfaces to
  multiple ERP systems and MES systems
• Empersas Polar
• Project to use XML schemas for schedule exchange
• Eli Lilly
• Projects to use ISA 95 models for manufacturing
  operations management architecture

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Building Collaborative Manufacturing Systems

• Process Used to Develop Solution Architectures
• Conceptual Topology
• Functional Areas
• Standards and Guidelines
• Standard Applications
• Logical Architecture Design
• Physical Architecture Design

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ISA 95 Control Hierarchy Levels
Level 4
Business Logistics Plant Production Scheduling,
Shipping, Receiving, Inventory, etc
ISA IEC/ISO Interface Standards
ISA Functional Model
Level 3
Manufacturing Operations Management Dispatching,
Detailed Production Scheduling, Production
Tracking, ...
IEC, OPC, OMAC Interface Standards
Level 2
Batch Production Control
Discrete Production Control
Continuous Production Control
Level 1
Level 0
The production processes
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Conceptual Topology IT View

• IT View of the ISA-95 Levels and relationship to
  systems and networks
• Levels 1-2
• Control the process and provide visibility to the
  process
• Electronic records are not embedded in the
  control layers (Level 1-2)
• Usually some specialized hardware and possibly
  networks
• Level 3
• Maintenance of production information is
  centralized to provide greater control and
  availability of the records
• Electronic records are managed and controlled
  through Level 3 systems with audit trail, access
  control, backup, and ERP connectivity
• Usually standard hardware and networks

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Conceptual Topology IT View
Level 4
ERP, APO, Logistics Systems
Business Process Information Network
Level 3
MES, LIMS, WMS, CMM Systems
Operations Information Network
Level 2
HMI, SCADA, Batch Systems
Automation Network
PLC, DCS, Packaged Systems
Level 1
Discrete Process Device Communication Networks
I/O, Devices, Sensors
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Functional Areas

• Use the ISA 95 and ISA 88 models of functions
• Map the functions to system areas and networks
• Use the ISA 95 rules for determining what is in
  Level 3 (vs Level 4)
• The function is critical to maintaining
  regulatory compliance.
• Includes such factors as safety, cGMP, and
  environmental compliance
• The function is critical to plant safety
• The function is critical to product quality
• The function is critical to plant reliability

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Functional Areas From ISA 95 88
Networking
Business Process Information Network
Level 3
Resource Management
Production Tracking
Detailed Scheduling
Product Definition Management
Production Dispatching
Configuration Management
Production Analysis
Production Execution
Networking
Operations Information Network
Level 2
Recipe Control
Supervisory Control
Alarm Management
Operator Control
Operator Visibility
Equipment Information Collection
Networking
Automation Network
Phase Control
On/Off Control
Continuous Control
Interlock Safety Control
Programmed Control
Level 1
Networking
Discrete Process Device Communication Networks
Sense Process
Sense Events
Manipulate Process
Manipulate Equipment
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Logical Architecture

• Maps functional areas and data locations
• Independent of technology
• Defines the different layers of the architecture
  in terms of data and control
• These are mapped to physical networks, servers,
  and applications in the physical architecture
• Defines what functions are to be performed at
  each level, and what data is to be maintained at
  each level
• To result in maintainable and robust systems
• To provide a way to manage the life cycle of the
  production systems
• Provides the structure required to grow and
  modify the system without compromising any of the
  previous advantages

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Logical Architecture IT View
Level 3
Reporting HMI
Engineering Tools
Reports and Analysis
Desktop
Investigations, Trends,
Diagnostics, analysis,
Business Information Network
Site Data Storage
ERP Connection
Fault tolerant
Centralized Servers
Permanent Database
MES
Operations Control
Level 2
Supervisory HMI
Recipe Execution
Operator Control
Batch Execution
Operations Information Network
Real-time Data and Buffering
Data Acquisition
Production Areas
Automation Network
Real-time Control and Data Collection
Controller
Packaged Equipment
Level 1
Device Connection /Networks
Sensors/Actuators
Process/Equipment
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A Physical Architecture

• Defines the IT infrastructure and applications
• Defines networks and network connections
• Defines locations of applications
• Defines locations of servers
• Defines the mapping of applications to servers
• Physical architecture depends on the solution set
  used
• Vendor capabilities
• Networks
• Security and network management

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Physical Architecture IT View
XML
Level 3
Site Information Network
VLAN Switch
2 way Firewall
Network Management Router
VLAN Switch
Non operations tools and views into data
Area Operations Information Network
Level 2
Ethernet
Network Management Router
HMI Viewer
One Instance Per Process Cell
Automation Network
Ethernet
Level 1
Network Management Router
Packaged Equip
PLC
DCS
Embedded PC
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Conclusions

• Linked execution systems deliver results!
• Reduced direct costs increased productivity
• Improved traceability reduced witch hunt
  expense
• Near-theoretical cycle times customer
  responsiveness, reduced WIP inventory
• Greater agility smaller lot sizes, more premium
  products in the mix, happier customers, happier
  shareholders!
• S95 defines the currency for manufacturing object
  and information exchange
• Faster project implementation cycles
• Flexibility to integrate and realign as corporate
  structures change

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Status

• ISA95.00.01 ISA.95.00.02 available
• IEC/ISO 62264-1 available from IEC ISO
• ISA 95.00.03 in draft
• Still under development in the committee
• World Batch Forum
• Developed XML Schemas for the exchanged
  information
• Vendors
• Many currently using ISA-95 models in development
  and current products
• Users
• Specifying ISA-95 in their RFPs